Isuzu I-280, I-350 2005-06

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the fuel tank into an approved container.
  8.  
  9. Raise and support the rear of the vehicle.
  10.  
  11. Remove or disconnect the following:

    Left rear tire
     
    Left rear inner fender liner
     
    Fuel filler tube from the fuel tank
     
    EVAP hose from the filler vent tube
     
    Electrical connectors and wiring harness retainers from the fuel tank
     
    Fuel return line and fuel filter
     
    Upper fuel tank retaining strap
     

  12.  
  13. Support the fuel tank.
  14.  
  15. Remove the lower tank retaining strap and lower the fuel tank.
  16.  
  17. Disconnect the fuel lines from the fuel pump module.
  18.  
  19. Using tool J-39765, rotate the fuel pump cam locking ring counterclockwise and remove the ring.
  20.  
  21. Raise the fuel pump and tilt it back to allow the fuel level sensor and float to clear the opening.
  22.  
  23. Remove and discard the fuel pump seal.

    Click image to see an enlarged view

    Fig. Fuel pump mounting in fuel tank

  24.  

To install:

  1. Install a new seal on the fuel pump.
  2.  
  3. Tilt the fuel pump until the fuel level sensor and float can enter the opening.
  4.  
  5. Lower the fuel pump and align the tang on the pump with the notch in the opening.
  6.  
  7. Using tool J-39765, rotate the fuel pump cam locking ring clockwise until fully seated.
  8.  
  9. Reconnect the fuel lines to the fuel pump module.
  10.  
  11. Raise the fuel tank and install the lower tank retaining strap.
  12.  
  13. Install or connect the following:

    Upper fuel tank retaining strap and tighten both strap bolts to 24 ft. lbs. (32 Nm)
     
    Fuel return line and fuel filter
     
    Electrical connectors and wiring harness retainers to the fuel tank
     
    EVAP hose to the vent tube
     
    Fuel filler tube to the fuel tank
     
    Left rear inner fender liner
     
    Left rear tire
     

  14.  
  15. Lower the vehicle.
  16.  
  17. Fill the tank with gasoline.
  18.  
  19. Turn the ignition ON for 10 seconds and then turn it OFF for 10 seconds. Again turn the ignition ON and check for leaks.
  20.  

 
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